Weber 500 LP User manual

SPIRIT

™

500 Series

LP Gas Barbecue

Serial Number

Please use this number in registering your warranty and

any correspondence with the factory.

Owner’s Manual

WARNING: Do not try to light this appliance

without reading "Lighting" instructions

section of this manual.

THIS GAS APPLIANCE IS DESIGNED FOR

OUTDOOR USE ONLY.

NOTICE TO INSTALLER: These instructions

must be left with the owner and the owner

should keep them for future use.

FOR YOUR SAFETY

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your

gas supplier or your fire department.

FOR YOUR SAFETY

1. Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance.

2. An LP tank not connected for use shall

not be stored in the vicinity of this or

any other appliance.

WARNING: Follow all leak check procedures

carefully in this manual prior to barbecue

operation. Do this even if barbecue was

dealer assembled.

National

Association

PROPANE

GAS

98567 10/97

DANGER

Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s Manual

may result in serious bodily injury or death, or in a fire or an explosion causing damage

to property.

WARNINGS

 Do not store a spare or disconnected LP tank under or near this barbecue.

 Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual.

 After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for gas leaks

and burner obstructions before using. See instructions in this manual for correct procedures.

 Do not operate the Weber Gas Barbecue if there is a gas leak present.

 Do not use a flame to check for gas leaks.

 Combustible materials should never be within 24 inches of the top, bottom, back or sides of your

Weber Gas Barbecue.

 Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue.

 Your Weber Gas Barbecue should never be used by children.

 You should exercise reasonable care when operating your Weber Gas Barbecue. It will be hot during

cooking or cleaning, and should never be left unattended.

 Should the burners go out during operation, turn all gas valves off. Open the lid and wait five minutes

before attempting to relight, using the lighting instructions.

 Do not use charcoal or lava rock in your Weber Gas Barbecue.

 Never lean over open grill or place hands or fingers on the front edge of the cooking box.

 Should a grease fire occur, turn off all burners and leave lid closed until fire is out.

 Do not enlarge valve orifices or burner ports when cleaning the valves or burners.

 The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.

 LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a

natural gas unit is dangerous and will void your warranty.

 Do not attempt to disconnect any gas fitting while your barbecue is in operation.

 Use heat-resistant barbecue mitts or gloves when operating barbecue.

LP GAS UNITS ONLY:

 Use the regulator that is supplied with your Weber Gas Barbecue.

 Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.

 A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.

Do not use an LP tank with a damaged valve.

 Although your LP tank may appear to be empty, gas may still be present, and the tank should be

transported and stored accordingly.

 If you see, smell or hear the hiss of escaping gas from the LP tank:

1. Get away from LP tank.

2. Do not attempt to correct the problem yourself.

3. Call your fire department.

Weber-Stephen Products Co. (Weber) hereby

warrants to the ORIGINAL PURCHASER of this

Weber Gas Barbecue that it will be free of

defects in material and workmanship from the

date of purchase as follows:

Aluminum Castings, 10 years,

Cooking Grates and Flavorizer Bars, 3 years,

All Remaining Parts, 5 years,

when assembled and operated in accordance

with the printed instructions accompanying it.

Weber may require reasonable proof of your

date of purchase. THEREFORE, YOU SHOULD

RETAIN YOUR SALES SLIP OR INVOICE.

This Limited Warranty shall be limited to the

repair or replacement of parts which prove

defective under normal use and service and

which on examination shall indicate, to Weber's

satisfaction, they are defective. Before returning

any parts, contact Weber-Stephen Products Co.

Customer Service Center. If Weber confirms the

defect and approves the claim, Weber will elect

to replace such parts without charge. If you are

required to return defective parts, transportation

charges must be prepaid. Weber will return parts

to the purchaser, freight or postage prepaid.

This Limited Warranty does not cover any failures

or operating difficulties due to accident, abuse,

misuse, alteration, misapplication, vandalism,

improper installation or improper maintenance or

service, or failure to perform normal and routine

maintenance, including but not limited to damage

caused by insects within the burner tubes, as set

out in this owner's manual.

Deterioration or damage due to severe weather

conditions such as hail, hurricanes, earthquakes

or tornadoes, discoloration due to exposure to

chemicals either directly or in the atmosphere, is

not covered by this Limited Warranty.

There are no other express warrants except as

set forth herein and any applicable implied

warranties of merchantability and fitness are

limited in duration to the period of coverage of

this express written Limited Warranty. Some

states do not allow limitation on how long an

implied warranty lasts, so this limitation may not

apply to you.

Weber is not liable for any special, indirect or

consequential damages. Some states do not

allow the exclusion or limitation of incidental or

consequential damages, so this limitation or

exclusion may not apply to you.

Weber does not authorize any person or

company to assume for it any other obligation or

liability in connection with the sale, installation,

use, removal, return, or replacement of its

equipment; and no such representations are

binding on Weber.

This Warranty applies only to products sold at

retail.

WEBER-STEPHEN PRODUCTS CO.

Customer Service Center

250 South Hicks Road

Palatine, IL 60067-6241

(800) 446-1071

LP Tank

The LP tank manufacturer is responsible for the

materials, workmanship and performance of the tank. If

the tank has a defect, malfunctions, or you have a

question regarding the tank, call the tank manufac-

turer's customer service center. The phone number is

on the warning decal which is permanently attached to

the tank. If the tank manufacturer has not resolved the

issue to your satisfaction, then call Weber-Stephen

Products Co., Customer Service Center.

WARRANTY

U.S. trademarks; Spirit, Gas Catcher, FlameCheck, and Spider

Stopper are U.S. trademarks of Weber-Stephen Products Co., 200

East Daniels Road, Palatine, IL 60067-6266. U.S.A. Spirit is

covered under the following patent nos.: U.S.A. #4,677,964;

4,727,853; #4,829,978; #4,941,817; and #4,966,125; Canada:

#1,279,540; #1,300,994; and #1,300,995. Printed in the U.S.A.

PATENTS AND TRADEMARKS

Contents

WARNINGS................................................................ 2

Warranty & Patents.................................................. 3-4

General Instructions.................................................... 6

Assembly............................................................... 7-20

Operating Instructions

Lighting........................................................ 21-22

Cooking............................................................ 23

Storage and/or Nonuse.................................... 23

Cleaning .......................................................... 23

LP Tank Information.................................... 24-26

Troubleshooting & Maintenance

Annual Maintenance......................................... 27

General Maintenance.................................. 28-29

Troubleshooting................................................ 31

Parts Listing.............................................................. 35

FEATURES:

a) Convenient tables and racks.

b) Heavy gauge porcelain-on-steel lid seals in heat.

c) Rapid read thermometer for precision cooking

measures grill temperature, and can be removed and

inserted into the food.

d) Heavy gauge steel Flavorizer Bars distribute heat

within the grill. Flavorizer Bars heat just the right

amount of drippings for flavoring, letting excess fat

drip past to help prevent flare-ups.

e) Separate burners for temperature control.

f) Crossover Ignition System with Gas Catcher Ignition

Chamber.

g) Fuel scale indicates LP gas supply.

h) Catch pan catches excess grease.

IMPORTANT NEW FEATURES:

Your Weber Gas Barbecue is equipped with a new and

improved LP tank connection, that has additional

safety features. They are:

1. The connection of the barbecue to the LP tank can be

made without the use of tools.

2. The new connection will not permit the flow of gas

until a positive gas connection is made.

3. If an accidental fire occurs at the LP tank connection,

the flow of gas is stopped by a temperature activated

shutoff.

4. If the LP supply hose becomes damaged, cut,

punctured, or accidentally fire damaged, the barbecue

connection is equipped with an excess flow control

that will limit the flow of gas if leakage or a fire occurs.

General Instructions

Your Weber Gas Barbecue is a portable outdoor cooking

appliance. With the Weber Gas Barbecue you can grill,

barbecue, roast and bake with results that are difficult to

duplicate with indoor kitchen appliances. The closed lid and

Flavorizer Bars produce that "outdoor" flavor in the food.

The Weber Gas Barbecue is portable so you can easily

change its location in your yard or on your patio. Portability

means you can take your Weber Gas Barbecue with you if

you move.

Liquid Propane (LP) gas supply is easy to use and gives

you more cooking control than charcoal fuel.

■ These instructions will give you the minimum

requirements for assembling your Weber Gas

Barbecue. Please read the instructions carefully

before using your Weber Gas Barbecue. Improper

assembly can be dangerous.

■ Not for use by children.

■ If there are local codes that apply to portable gas grills,

you will have to conform to them. If there are no local

codes, you must conform to the latest edition of the

National Fuel Gas Code: ANSI Z 223.1.

■ The pressure regulator supplied with the Weber

Gas Barbecue must be used. This regulator is set

for 10.5 inches of water column (pressure).

■ This Weber Gas Barbecue is designed for use with

liquid propane (LP) gas only. Do not use with natural

(piped in city) gas. The valves, orifices, hose and

regulator are for LP gas only.

■ Do not use with charcoal fuel.

■ Check that the area under the control panel and the

bottom tray are free from debris that might obstruct

the flow of combustion or ventilation air.

■ The area around the LP tank must be free and clear

from debris.

For Installation in Canada

These instructions, while generally acceptable, do not

necessarily comply with the Canadian Installation codes,

particularly with piping above and below ground. In

Canada the installation of this appliance must comply with

local codes and/or Standard CAN/CGA-B149.2 (Installation

Code for Propane Burning Appliances and Equipment).

Storage

■ The gas must be turned OFF at the LP tank when the

Weber Gas Barbecue is not in use.

■ When the Weber Gas Barbecue is stored indoors, the

gas supply must be disconnected and the LP tank

stored outdoors in a well-ventilated space.

■ LP tanks must be stored outdoors in a well-ventilated

area out of the reach of children. Disconnected LP

tanks must not be stored in a building, garage or any

other enclosed area.

■ When the LP tank is not disconnected from the Weber

Gas Barbecue, the appliance and LP tank must be

kept outdoors in a well-ventilated space.

Operating area

WARNING: Only use this barbecue outdoors in a

well ventilated area. Do not use in a garage, building,

breezeway or any other enclosed area.

■ Never use your Weber Gas Barbecue under an

unprotected combustible roof or overhang.

■ Your Weber Gas Barbecue is not intended to be

installed in or on recreational vehicles and/or boats.

■ Do not use combustible materials within 24 inches of

the top, bottom, back or sides of the grill.

■ The entire cooking box gets hot when in use. Do not

leave unattended.

■ Keep any electrical supply cord and the fuel supply

hose away from any heated surface.

■ Keep the cooking area clear of flammable vapors

and liquids, such as gasoline, alcohol, etc., and

combustible materials.

■ Never store an extra (spare) LP tank under or near

the Weber Gas Barbecue.

Step 1

Check package contents

Cooking box

(assembly)

Lid

(assembly)

LP tank

Bottom tray

Two cooking grates

LP tank filler adapter

Control panel

Assembly

Tools needed

Hammer

7/16 open-end or an adjustable wrench

Pliers

Block of wood

Supplies needed

Your LP tank is shipped empty for safety. After setting the

LP fuel scale you will need to fill it. (See Step "Fill LP tank.")

You will need a soap and water solution to check for gas

leaks. (See Step "Check for gas leaks.")

Note - The hardware size of nuts, bolts and screws is

given. For example "1/4-20 x 2 inch bolt" means a bolt

1/4 inch in diameter with 20 threads to the inch, 2 inches

long. On a small screw for example, "6-32 x 1/2 inch

screw" means a number 6 screw, with 32 threads to the

inch, 1/2 inch long.

While we give much attention to our products,

unfortunately an occasional error may occur. If a part is

missing, do not go back to the store. Call the Weber

Customer Service Center toll free 1-800-446-1071 to

receive immediate assistance. Have your owner’s manual

and serial number of the barbecue available for reference.

Phillips Screwdriver

Left frame

Right frame

Wheel frame

Leg frame

Frame connector

Molded work table

Accessory rack

Warming rack

Five Flavorizer Bars

Tank panel assembly

Front panel

Catch pan holder

Catch pan

Two drip pans

Manifold bracket

Thermometer

Two wheels

Fuel scale assembly

Two plastic buttons

(actual size)

Two 1/4-20 wing nuts

(actual size)

Ten 1/4 inch nylon washers

Two hair pin cotters

Two wheel hubcaps

Work table spacer

1/4-20 keps nut

Check contents of hardware packs

Two burner control knobs

Two tool holders

Eight tubing plugs

(two are spares)

Two hinge pins

(hardware size: 1/4 x 1 1/2 inch clevis pin)

(actual size)

1/4-20 x 2 inch bolt

(actual size)

Two 1/4-20 x 1 3/4 inch bolts

(actual size)

Six 1/4-20 x 1/2 inch bolts

(actual size)

Two Phillips screws/washers

Figure 1

Step 2

Assemble wheel frame

You will need: wheel frame, two wheels, two wheel hubcaps,

hammer and a block of wood.

Set one end of wheel frame on the block of wood (or other

hard, protected surface). Put one wheel on axle, WEBER

side facing up, and tap on one hubcap.Figure 1.

Repeat with other wheel and hubcap.

Figure 2

Step 3

Assemble top frame

You will need: left frame, right frame, two 1/4-20 x 1/2 inch

bolts, two nylon washers and a 7/16 inch wrench.

Note - Work on carpeted area (on grass or one of the

boxes) to protect the finish during frame assembly.

Lay the leg pieces as shown so the leg tabs point up.

Figure 2.

Slip the two frame pieces together with the tabs inside.

Figure 2 (a). Slip washers on bolts, insert bolts as shown

and tighten. Figure 2 (b). (If you try to insert a bolt and

there are no holes, you have the left frame turned the

wrong way. Turn the left frame around.)

Leg tabs

Frame tabs

(a)

(b)

Right frame

Left frame

Figure 3

Step 4

Continue frame assembly

You will need: leg frame, wheel frame, four 1/4-20 x 1/2 inch

bolts, four nylon washers and a 7/16 inch wrench.

Place the leg frame onto the tabs of the left frame with the

dimple to the inside. Figure 3. Place the wheel frame onto

the tabs of the right frame with the dimple to the inside. The

fuel scale decal should face away as shown. Figure 3.

The leg tabs must be on the inside of the frames.

Add the washers to the bolts, insert in the holes as shown

and tighten with the wrench. Figure 3.

Figure 4

Step 5

Install tubing plugs

You will need: two tubing plugs and a hammer.

Insert tubing plugs into the ends of the leg frame.Figure 4.

To fully seat the plugs, you may have to tap them lightly

with a hammer.

Figure 5

Step 6

Add front panel

You will need: front panel and two plastic buttons.

Turn frame assembly right side up.

Align the panel with the holes in the frame and insert the

plastic buttons through the front panel and frame. Figure 5.

View from rear

of barbecue

Dimples to

the inside

Fuel scale

decal

Plastic buttons

Your Weber Gas Barbecue burner assembly has been

factory assembled, pressure and flame tested. As a safety

precaution we recommend you check the burner alignment:

a) Do the valves fit into the ends of the burners?

Figure 8 (a).

b) Are the ends of the burners under the washers at the

left rear and left front of the cooking box? The screws

are only guides. Do not tighten. Figure 8 (b).

c) Are the wing nuts under the burner assembly hand

tight? Do not tighten with pliers. Figure 8 (c).

If you answered YES to a, b and c, the burners are

correctly aligned. If you answered NO, the burners are

misaligned. Contact Weber-Stephen Customer Service.

Do not use barbecue.

Guide screw

(a)

(b)

(c)

Wing Nuts

View from

behind

cooking

box

Figure 8

Figure 6

Step 7

Add cooking box

You will need: frame assembly, cooking box assembly, work

table spacer, 1/4-20 keps nut, 1/4-20 x 2 inch bolt, pliers

and a 7/16 inch wrench.

Uncoil the hose.

Set the cooking box in the frame so the burner tubes are

under the frame brace. Figure 6.

Burner tubes

Frame brace

Slide the cooking box to the left within the frame. Hold the

work table spacer up to the frame. Insert the bolt through

the hole in the work table spacer, frame, and cooking box

with the head of the bolt outside the box. Figure 7. Add

keps nut. Tighten by holding the bolt with pliers while you

tighten the nut with a wrench.

Figure 7

Frame brace

Manifold bracket

Figure 9

Step 8

Install manifold bracket

You will need: manifold bracket

Hook the bracket onto the manifold at approximately the

center of the length of the manifold. Place your hand

underneath the bracket. Lift the manifold, bracket and

cooking box slightly and hook the tab of the bracket onto

the frame brace. Figure 9.

Step 9

Install tank panel assembly and frame connector

You will need: tank panel assembly, frame connector, two

1/4-20 x 1 3/4 inch bolts, two nylon washers and a 7/16 inch

wrench.

Insert the tank panel tabs into the slots in the frame brace.

Figure 10.

Figure 10

Figure 11

Frame

connector

Cross brace

Tank panel tabs

Slots in frame brace

Frame brace

Slide tank panel up until notch at bottom of panel fits over

the cross brace. Insert one bolt with washer through the

hole in the bottom of the tank panel, through the wheel

frame and into the end of the frame connector. Insert the

other bolt with washer through the leg frame and into the

other end of the frame connector. Hold the frame connector

square and tighten the bolts. Figure 11.

Step 10

Add fuel scale assembly

You will need: fuel scale assembly, two 1/4-20 wing nuts

and two nylon washers.

Slip the bolts on the back of the fuel scale assembly through

the two small holes in the tank panel. Make sure indicator

rod of fuel scale is on the left side of the wheel frame.

Add washers then wing nuts and tighten. Figure 12.

Figure 12

View from front rightView from front left

Step 11

Install igniter

Note - The igniter wires are already attached to the Gas

Catcher Ignition Chamber and the igniter. This was done to

factory test the ignition system.

The igniter lock nut is on the igniter.

Insert the top of the igniter up through the large part of the

keyhole in the frame brace. Figure 13 (b).Loosen the igniter

lock nut and slide the igniter into the small part of the

keyhole. Figure 13 (c). Tighten the igniter lock nut. Figure 13.

Note - If the igniter works loose, carefully tighten the igniter

lock nut with an adjustable wrench or pliers.

Figure 13

Igniter lock nut

Small part of keyhole

in frame brace

Frame brace

Keyhole in

frame brace

(a)

(b)

(c)

Step 12

Set LP fuel scale

You will need: LP tank (empty).

Note - For accuracy, the fuel scale must be set with an

empty tank.

We utilize various LP tank manufacturers. Some of the

tanks we receive have differing top collar assemblies.

(The top collar is the metal protective ring around the

valve.) One series of tanks mounts with the valve facing

front. The other tanks mount with the valve facing away

from the fuel scale. These types of tanks are illustrated in

Figure 14.

Loosen the tank lock wing nut. Tighten so the lock is held

up out of the way. Figure 14 (a). Lift and hook the tank onto

the fuel scale. With an empty LP tank, adjust the fuel scale

setting to E with scale setting (top) wing nut. Figure 14 (b).

CAUTION: Do not remove adjustment wing nut from

tank scale.

After adjusting tank scale, push tank down a couple of

times to check that the tank scale is set on “E”.

Figure 14

Tank lock

wing nut

(a) (b)

Scale setting

wing nut

Step 13

Fill LP tank

Note - The LP tank manufacturer is responsible for the

materials, workmanship and performance of the tank. If

the tank has a defect, malfunctions, or you have a

question regarding the tank, call the tank manufacturer's

customer service center. The phone number is on the

warning decal which is permanently attached to the tank.

If the tank manufacturer has not resolved the issue to your

satisfaction, then call Weber-Stephen Products Co.,

Customer Service Center.

To fill, take the LP tank and filler adapter to an RV center

or look up gas-propane in the phone book for other

sources of LP gas.

WARNING: We recommend that your LP tank be

filled at an authorized LP gas dealer by a qualified

attendant, who fills the tank by weight.

IMPROPER FILLING IS DANGEROUS.

Tell your LP dealer that this is a new LP tank. The air must

be removed from a new LP tank before the initial filling.

Your LP tank dealer is equipped to do this.

WARNING: If you exchange your LP tank, make

sure you get a similar tank in return. Your LP tank is

equipped with a quick-disconnect valve and an OPD

(Overfilling Prevention Device). Other LP tanks are not

compatible with your barbecue connection.

The LP tank must be installed, transported and stored in

an upright position. LP tank should not be dropped or

handled roughly.

Never store or transport the LP tank where temperatures

can reach 125° Fahrenheit (too hot to hold by hand – for

example: do not leave the LP tank in a car on a hot day).

For full instructions on safe handling of LP tanks, see

Section "Safe handling tips for LP gas".

Route the hose so it will not interfere with the scale

indicator rod.

The hose and regulator are connected in the following

manner:

Slide back the collar of the quick disconnect on the tank

valve. Push the male fitting of the regulator into the quick

disconnect, and maintain pressure. Slide the collar closed.

Figure 17 (a). Figure 17 (b) shows the quick disconnect

engaged and various components of the tank and

regulator. Regulator vent hole should be at 3, 6, or 9

o'clock. It should not be pointed up. Figure 17 (c).

Figure 17

Turn so regulator vent

does not collect water

Hose

Tank lock

wing nut

Quick disconnect

engaged

Valve handwheel

close clockwise

Tank valve

Collar

Male

fitting

Pressure

relief valve

Tank

Regulator

vent

(a)

(b)

(c)

Step 15

Connect LP tank

WARNING: Make sure that the LP tank valve is

closed. Close by turning clockwise.

Hook the LP tank onto the fuel scale. Loosen the tank lock

wing nut. Swing the tank lock down. Tighten the wing nut.

Figure 16.

Step 14

Check that all burner valves are off

You will need: one burner control knob.

Valves are shipped in the OFF position, but you should

check to be sure. Put the knob on each valve. Check by

pushing down and turning clockwise. If they do not turn

they are off, proceed to the next step. Figure 15.

Figure 16

Figure 15

WARNING: You should check for gas leaks every

time you disconnect and reconnect a gas fitting.

Note - All factory made connections have been thoroughly

checked for gas leaks. The burners have been flame

tested. As a safety precaution you should recheck all

fittings for leaks before using your Weber Gas Barbecue.

Shipping and handling may have loosened or damaged a

gas fitting.

WARNING: Perform these leak checks even if your

barbecue was dealer or store assembled.

You will need: a soap and water solution and a rag or

brush to apply it.

To perform leak checks: open tank valve by turning the

tank valve handwheel counterclockwise. Figure 18.

Figure 18

 DANGER

Do not use an open flame to check for gas

leaks. Be sure there are no sparks or open

flames in the area while you check for

leaks. This will result in a fire or explosion

which can cause serious bodily injury or

death and damage to property.

Check:

a) Hose to manifold connection. Figure 19 (a).

b) Regulator to tank connection. Figure 19 (b).

WARNING: If there is a leak at connection (a)

retighten the fitting with a wrench and recheck for

leaks with soap and water solution.

If a leak persists after retightening the fitting, turn OFF

the gas. DO NOT OPERATE THE BARBECUE. Contact

Weber-Stephen Customer Service.

c) Valves to manifold connections. Figure 19 (c).

d) The hose to regulator connection. Figure 19 (d).

WARNING: If there is a leak at connections

(b), (c) or (d), turn OFF the gas. DO NOT OPERATE

THE BARBECUE. Contact Weber-Stephen Customer

Service.

When leak checks are complete, turn gas supply OFF and

rinse connections with water.

Check for leaks by wetting the connections with the soap

and water solution and watching for bubbles. If bubbles

form or if a bubble grows there is a leak.

Note - Since some leak test solutions, including soap and

water, may be slightly corrosive, all connections should be

rinsed with water after checking for leaks.

WARNING: Do not ignite burners when leak checking.

(a)

Figure 19

(c)

(d)

(b)

Step 16

Check for gas leaks

Step 17

Install Flavorizer Bars and Cooking Grates

You will need: five Flavorizer Bars and two cooking grates.

Set the Flavorizer Bars side to side in the cooking box.

Figure 20.

Figure 20

Set the cooking grates onto the ledges in the cooking box

with the rounded side up. Figure 21.

Figure 21

Step 18

Install the bottom tray

You will need: bottom tray, catch pan holder, catch pan and

one drip pan.

Figure 23

Figure 22

Figure 24

Bottom tray

Finger grip on front

edge of bottom tray

Finger grip

Front side of catch

pan holder

Put the foil drip pan into the catch pan.

Slide the catch pan into the catch pan holder with its finger

grip towards you.

Slide the bottom tray onto the mounting rails under the

cooking box with finger grip toward you. Figure 24.

CAUTION: Do not line bottom tray with aluminum foil.

It can cause grease fires by trapping the grease and not

allowing grease to flow into the catch pan.

Hook the ends of the catch pan holder into the hole in the

bottom tray. Figure 23. The front of the catch pan holder

must be on the same side as the finger grip of the

bottom tray.

Step 19

Install Lid

You will need: lid, two hinge pins and two hair pin cotters.

Set the lid in place. Align the hinges at the rear of the

barbecue. Insert hinge pins from the outside. Insert hair pin

cotters into the small holes in the hinge pins. Figure 25.

Hair pin cotter

Hinge pin

Figure 25

Step 20

Add tool holders, control panel and burner

control knobs

You will need: two tool holders, control panel, two Phillips

screws/washers, a Phillips screwdriver, and two burner

control knobs.

Hook the tool holders over the frame rail. Figure 26.

Set the control panel in place over both frame braces.

(Hold the Crossover Ignition button up while setting the

control panel in place.) Line up the holes in the control

panel with the holes in the inserts in the frame brace. Insert

screws and tighten with Phillips screwdriver until snug. Do

not overtighten. Figure 26 (a).

Push on the burner control knobs. Figure 26 (b).

Figure 26

Tool holders

Insert in

frame brace

Control panel

Phillips screws/

washers

(a)

(b)

Crossover

Ignition

Button

Step 21

Complete accessory installation

You will need: work table, accessory rack, warming rack,

four tubing plugs and thermometer.

Set the accessory rack across the bottom braces in front

of the frame connector. Figure 27 (a).

Open the lid and set the warming rack into the slots at the

rear of the cooking box. Figure 27 (b).

Set the work table onto the left side rails and work table

spacer. Figure 27 (c).

Note: Work table should rest between the frame rails and on

the work table spacer installed in “Add cooking box” step.

Insert the thermometer into its holder. Figure 27 (d).

Insert the tubing plugs into the ends of the frame. To fully

seat the plugs, you may have to tap them lightly with a

hammer. Figure 27 (e).

Figure 27

(a)

(d)

(b)

(e)

(c)

Work table

spacer

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Weber 500 LP, 551201, 98567, Spirit 520 Skyline LP User manual

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